2004 YAMAHA VERSITY 300 check engine light

3
INSTRUMENT AND CONTROL FUNCTIONS
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Fuel gauge
The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards "E" (Empty) as the fuel level
decreases. When the remaining fuel in
the tank reaches approximately 1.9 L, the
fuel level warning light will come on and
the multi-function display will
automatically change to the "Trip/Fuel"
mode. (See page 3-4 — 3-5 for details.).
If this occurs, refuel as soon as possible.
NOTE :
Do not allow the fuel tank to empty itself
completely.
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Battery voltage/coolant
temperature gauge
When the key is turned to "", this
gauge indicates the battery voltage
level before the engine was stopped.
NOTE :
If the needle drops to the "9V" mark,
have a Yamaha dealer check the
battery.When the key is turned to "
", this
gauge indicates the coolant
temperature. If the needle reaches the
red zone, stop the scooter and allow
the engine to cool. (See page 6-17 for
details.)
EC000002
Do not operate the engine if it is
overheated.
CAUTION:
1. Fuel gauge
2. Fuel warning light1. High level
2. Low level1. Red zone
O1O1O
2O2O
4O4O
6O6O
F
1/21/2
E
1
2
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3-3
10O10O
12O12O
14O14O
16O16O
H
C15V15V
9V9V
1
2
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10O
12O
14O
16O
H
C15V 15V
9V 9V1
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INSTRUMENT AND CONTROL FUNCTIONS
3
1
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EAU00330
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
scooter upright.
NOTE :
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation
of the ignition circuit cut-off system.)
EW000044
The scooter must not be ridden with
the sidestand down, or if the
sidestand cannot be properly moved
up (or does not stay up), otherwise
the sidestand could contact the
ground and distract the operator,
resulting in a possible loss of
control. Yamaha’s ignition circuit cut-
off system has been designed to
assist the operator in fulfilling the
responsibility of raising the
sidestand before starting off.
Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
1. Sidestand switch
WARNINGEAU00337
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch and
brake light switches) has the following
functions.
•It prevents starting when the
sidestand is up, but neither brake
is applied.
•It prevents starting when either
brake is applied, but the sidestand
is still down.
•It cuts the running engine when
the sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EW000045
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
WARNING
3-16

OPERATION AND IMPORTANT RIDING POINTS
5
EAU04755
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
•Avoid high engine speeds during
acceleration.
•Avoid high engine speeds with no
load on the engine.
•Turn the engine off instead of
letting it idle for an extended
length of time (e.g., in traffic jams,
at traffic lights or at railroad
crossings).
EAU01128
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this
reason, you should read the following
material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the
engine wear and polish themselves to
the correct operating clearances.
During this period, prolonged full-
throttle operation or any condition that
might result in engine overheating must
be avoided.
EAU03845*
0 — 1,000 km
Avoid prolonged operation above 1/3
throttle.
1,000 — 1,600 km
Avoid prolonged operation above 1/2
throttle.
ECA00138
After 1,000 km of operation, be sure
to replace the engine oil and final
transmission oil.
1,600 km and beyond
The vehicle can now be operated
normally.
EC000049
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
CAUTION:
CAUTION:
5-4

EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ........................................................ 6-1
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing cowlings and panels ........ 6-5
Checking the spark plug ....................................... 6-11
Engine oil .............................................................. 6-13
Final transmission oil ............................................ 6-16
Coolant .................................................................. 6-17
Air filter and the V-belt case air filter elements ...... 6-18
Adjusting the carburetor ........................................ 6-20
Adjusting the throttle cable free play ..................... 6-20
Adjusting the valve clearance ............................... 6-21
Tires ...................................................................... 6-21
Cast wheels .......................................................... 6-23
Adjusting the front and rear brake lever
free play ................................................................ 6-23
Checking the front and rear brake pads ................ 6-24
Checking the brake fluid level ............................... 6-24
Changing the brake fluid ....................................... 6-25Checking and lubricating the cables ..................... 6-26
Checking and lubricating the throttle grip
and cables ............................................................. 6-26
Lubricating the front and rear brake levers ........... 6-26
Checking and lubricating the centerstand
and sidestand ........................................................ 6-27
Checking the front fork .......................................... 6-27
Checking the steering ........................................... 6-28
Checking the wheel bearings ................................ 6-29
Battery ................................................................... 6-29
Replacing the fuses .............................................. 6-30
Replacing a headlight bulb .................................... 6-32
Replacing a front turn signal light bulb .................. 6-34
Replacing tail/brake light bulb
or rear turn signal light bulb .................................. 6-34
Replacing the license plate light bulb .................... 6-35
Troubleshooting ..................................................... 6-35
Troubleshooting charts .......................................... 6-36
6

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Change. (See page 3-7 for more information about the√When the oil change indicator comes on19 Engine oil oil change indicator)( Every 3000 km)
•Check oil level and vehicule for oil leakage. Every 3,000 km√
20 * Engine oil strainer•Clean.√
21 * Cooling system•Check coolant level and vehicule for coolant leakage.√√√√ √•Change. Every 3 years
22Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
23 * V-belt•Replace. Every 20,000 km
24 *Front and rear brake
•Check operation.√√√√√ √
switches
25 Moving parts and cables•Lubricate.√√√√ √
Throttle grip housing•Check operation and free play.
26 *
and cable•Adjust the throttle cable free play if necessary.√√√√ √
•Lubricate the throttle grip housing and cable.
27 *Lights, signals•Check operation.
√√√√√ √
and switches•Adjust headlight beam.
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
EAU03884*
NOTE :
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Remove the spark plug as shown,
with the spark plug wrench
included in the owner's tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the scoo-
ter is ridden normally).
NOTE :
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the scooter.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
DR8EA (NGK)To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
Spark plug gap:
0.6 – 0.7 mm
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
1. Spark plug wrencha. Spark plug gap
6-12
1
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a
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PERIODIC MAINTENANCE AND MINOR REPAIR
6Tightening torque:
Spark plug:
17.5 Nm (1.75 m
•kg)
NOTE :
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 – 1/2 turn
past finger tight. However, the spark
plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.
5. Install the cowling.
6-13
EAUM0103*
Engine oil
The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals
specified in the periodic maintenance
and lubrication chart and when the oil
change indicator comes on.To check the engine oil level
1. Place the scooter on the
centerstand.
NOTE :
Make sure that the scooter is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04591*
Coolant
The coolant reservoir is located under
the panel B. (See page 6-9 for panel
removal and installation procedures.)
To check the coolant level
1. Place the scooter on a level sur-
face and hold it in an upright posi-
tion.
NOTE :
•The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
•Make sure that the scooter is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.2. Check the coolant level in the
coolant reservoir.
NOTE :
The coolant should be between the
minimum and maximum level marks.
1. Maximum level mark
2. Minimum level mark
3. If the coolant is at or below the
minimum level mark, remove the
reservoir cap, add coolant to the
maximum level mark, and then
install the reservoir cap.
Coolant reservoir capacity:
0.4 L
4. Install the panel.
1. Coolant reservoir cap
6-17
1
2
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1
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